Skin material and method for manufacturing the same

Abstract

The surface covering material (1) comprises a base material (2) having a recessed portion (4) on the front surface (3) thereof. The base material (2) includes a colored portion (5) having a second color in the recessed portion (4). The second color is different from a first color of the base material (2). The colored portion (5) contains a coloring agent and a binder resin. The binder resin contains a polycarbonate-based polyurethane resin and contains one or both among a urethane resin having a softening temperature of between 120°C and 220°C inclusive, and an acrylic resin having a glass transition temperature of between -30°C and 50°C inclusive.

Description

[Technical Field]

[0001] The present invention relates to a skin material. [Background technology]

[0002] Patent Document 1 discloses a method for applying a three-dimensional pattern. This method is intended for carpet substrates or blanket substrates. In this method, a hot-melt resin is applied to the raised surface of an embossing roll, and the embossing roll is pressed against the substrate surface at a temperature equal to or higher than the melting point of the hot-melt resin. In this method, a desired colorant is blended into the hot-melt resin, and the recessed portions are colored simultaneously with the formation of the recessed and raised portions. Patent Document 1 discloses that this method makes it possible to relatively easily obtain colorful three-dimensional patterns. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Unexamined Patent Publication No. 114992 / 1983 Summary of the Invention [Problem to be solved by the invention]

[0004] A skin material is provided on the front side of a given product to form the surface of the product. Therefore, the skin material is required to have a design. The inventors thought that the design of the skin material could be improved by forming a recess on the surface of the skin material and providing a colored portion in this recess.

[0005] In this regard, the inventors considered that it is important for the skin material that forms the surface of the product to have a difference in feel between the colored portion and the uncolored portion. For example, the inventors considered it undesirable for the colored portion to feel significantly harder than the uncolored portion. Furthermore, the inventors considered that the light resistance and heat resistance of the colored portion that decorates the recesses may be important. Therefore, the inventors investigated ways to improve the feel, light resistance, and heat resistance of the colored portion in addition to the above-mentioned design.

[0006] In addition, the inventors noticed that since the skin material forms the surface of the product, some object may come into contact with the colored portion. The inventors thought that the abrasion resistance of the colored portion decorating the recessed portion may be important. Therefore, the inventors investigated ways to improve the abrasion resistance of the colored portion in addition to the design mentioned above.

[0007] The object of the present invention is to provide a surface material having a design. And the manufacturing method of this skin material The purpose is to provide [Means for solving the problem]

[0008] One aspect of the present invention includes a substrate having a recess having a bottom surface and an inner peripheral surface on a surface of a first color, the substrate comprising: In the thickness direction of the substrate Front side becomes a surface member having a surface forming a surface of the substrate; The thickness direction and a cushion member made of polyurethane foam laminated on the back side. * a * b * ΔE in color space * ab includes a colored portion of a second color that is different in the range of 26 to 31, the inner circumferential surface has a first portion on a first side in a first direction perpendicular to the thickness direction, the first portion inclining from a second side in the first direction toward a front side from a back side in the thickness direction to a first side, and a second portion on a second side in the first direction inclining from the first side in the first direction toward a front side from a back side in the thickness direction to a second side, and a dimension in the first direction of an opening end of the recess that is on the front side in the thickness direction is set to be larger than a dimension in the first direction of the bottom surface, The colored portion is a skin material that includes a colorant and a binder resin, and the binder resin includes one or both of a urethane resin that includes a polycarbonate-based polyurethane resin and has a softening temperature of 120°C or more and 220°C or less, and an acrylic resin that has a glass transition temperature of -30°C or more and 50°C or less, and the colored portion is not provided on the inner surface but is provided on the bottom surface.

[0009] This skin material allows the recesses to be decorated with colored portions, the texture of the colored portions to be the same as or close to the texture of the non-colored portions, and light resistance and heat resistance to be ensured.

[0011] Furthermore, this Skin materialAccording to the present invention, the difference between the first color and the second color can be clearly seen. For example, a viewer of the skin material can distinguish the colored portion on the surface of the substrate and can recognize the colored portion in the recess.

[0012] Another aspect of the present invention is The substrate is a laminate including a surface member having a recessed portion having a bottom surface and an inner peripheral surface on a surface of a first color, the surface member being a surface of the substrate, and a cushion member made of polyurethane foam laminated on the back side of the surface member, and the recessed portion is different from the first color in L. * a * b * ΔE in color space * a colored portion having a second color where ab varies within a range of 26 to 31, the colored portion including a colorant and a binder resin, the binder resin including one or both of a urethane resin that includes a polycarbonate-based polyurethane resin and has a softening temperature of 120°C or more and 220°C or less, and an acrylic resin that has a glass transition temperature of -30°C or more and 50°C or less, the colored portion being provided on the bottom surface but not on the inner circumferential surface, This method for producing a skin material includes the steps of: bringing the surface of the substrate into contact with a pressing member at a first temperature of 80°C or less, the pressing member holding a colorant-containing composition containing the second colorant and including an embossed portion having a shape corresponding to the recess; and bringing the back of the substrate into contact with a receiving member at a predetermined second temperature; placing the substrate between the pressing member and the receiving member; pressing the embossed portion against the substrate to form the recess; and, with the embossed portion pressed against the substrate, forming the colored portion simultaneously with the recess using the colorant-containing composition held by the embossed portion.

[0013] This skin material Manufacturing method According to the present invention, the recessed portion can be decorated with the colored portion, and the abrasion resistance of the colored portion can be improved. [Effects of the Invention]

[0014] According to the present invention, a decorative skin material And the manufacturing method of this skin material can be obtained. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a perspective view showing an example of a schematic configuration of a skin material according to an embodiment. [Figure 2] 2 is a side cross-sectional view showing an example of a schematic configuration of a recess in the skin material of FIG. 1. The cutting position is line II in FIG. [Figure 3] FIG. 2 is a plan view showing an example of a schematic configuration of a pressing member used in an experiment of an example. [Figure 4]4 is an enlarged side view of the embossing part of the pressing member as seen from the direction A in Fig. 3. Fig. 4 shows an example of the schematic configuration of the embossing part. DETAILED DESCRIPTION OF THE INVENTION

[0016] Embodiments for carrying out the present invention will be described with reference to the drawings. The present invention is not limited to the configurations described below, and various configurations can be adopted within the same technical concept. For example, some of the configurations shown below may be omitted or replaced with other configurations. The present invention may also include other configurations. The drawings schematically show specific configurations. The correspondence between the drawings and other drawings or the numerical values ​​specified below that identify the configurations in the drawings may not be exact. Hatching indicates a cross section.

[0017] <Skin material 1> The skin material 1 includes a substrate 2 (see FIGS. 1 and 2). In this embodiment, the front surface of the substrate 2 is referred to as the "surface 3." The substrate 2 of the skin material 1 has recesses 4 on the surface 3, and the recesses 4 include colored portions 5 of a second color. The second color is different from the first color of the substrate 2. The colored portions 5 include a binder resin. The binder resin includes one or both of a urethane resin and an acrylic resin.

[0018] The substrate 2 includes a front member 21, a cushion member 22, and a back member 23 (see FIGS. 1 and 2). The front member 21, cushion member 22, and back member 23 are layered in this order from the front side of the substrate 2. The front surface of the front member 21 forms the surface 3. The surface 3 forms the front surface of the covering material 1 with the recesses 4 formed in the substrate 2. The surface 3 is the front surface of the substrate 2 and also the front surface of the covering material 1. The recesses 4 are provided on the surface 3 of the covering material 1 (see FIGS. 1 and 2). The surface 3 of the covering material 1 forms the design surface, which is visible to a viewer of the covering material 1.

[0019] 2 indicates that the colored portion 5 is of a second color and that the colored portion 5 has been cut as described above. The second color of the colored portion 5 may be black, but the black hatching in FIG. 2 does not mean that the second color of the colored portion 5 is limited to black. The color of the colored portion 5 is determined appropriately depending on the design required for the covering material 1.

[0020] In the embodiments, the thickness direction of the skin material 1, the base material 2, the front member 21, the cushion member 22, and the back member 23 is simply referred to as the "thickness direction" (see Figures 1 and 2). The direction in which the front member 21, the cushion member 22, and the back member 23 are stacked on the base material 2 coincides with the thickness direction. In this case, one side in the thickness direction on which the front member 21 is provided on the base material 2 becomes the front side of the skin material 1 and the base material 2. In the embodiments, accordingly, one side in the thickness direction is referred to as the front side in the thickness direction. Furthermore, the side opposite to the front side in the thickness direction is referred to as the back side in the thickness direction. The back member 23 of the base material 2 is provided on the back side in the thickness direction. The back surface of the skin material 1 and the base material 2 in the thickness direction is referred to as the "back surface." The back surface is the back surface of the base material 2 and also the back surface of the skin material 1.

[0021] The back surface of the substrate 2 of the skin material 1 does not have a recess (see FIG. 2). However, recesses may be provided on both the front and back surfaces of the substrate 2 of the skin material 1. In this case, the recesses on the back surface may be provided at positions corresponding to the recesses 4 on the front surface 3. For example, the recesses on the back surface are provided on the back surface of the substrate 2 on the back side of the recesses 4 on the front surface 3 in the thickness direction.

[0022] The colored portion 5 is provided on a part or all of the recess 4. In the embodiment, the colored portion 5 is provided on the bottom surface of the recess 4, but not on the wall surfaces W1, W2, W3, and W4 of the recess 4 (see FIGS. 1 and 2). The wall surfaces W1, W2, W3, and W4 form the annular inner peripheral surface of the recess 4 (see FIG. 1). However, such an arrangement of the colored portion 5 in the recess 4 is merely an example. The colored portion 5 may be provided on the inner peripheral surface of the recess 4. The colored portion 5 may be provided on part or all of one or both of the bottom surface and the inner peripheral surface of the recess 4. Assume that the colored portion 5 is provided on the wall surface W1 as part of the inner peripheral surface of the recess 4. In this case, the colored portion 5 may be provided on the entire wall surface W1 or on a part of the wall surface W1.

[0023] From the viewpoint of forming a textured pattern, it is preferable that the substrate 2 contains a thermoplastic material in part thereof. The substrate 2 does not have to be a three-layer laminate. The substrate 2 may be a single-layer sheet material rather than a laminate. The substrate 2 may be a two-layer or four or more-layer laminate. The member laminated to the front member 21 in the substrate 2 may be one of the cushion member 22 and the back member 23, or may be a member different from one or both of the cushion member 22 and the back member 23.

[0024] When the substrate 2 is a laminate, the method for forming the laminate is not particularly limited. Examples of methods for forming the laminate include a method using an adhesive and a method using frame lamination. The inventors believe that the method using frame lamination is preferable from the viewpoints of process load and weight reduction.

[0025] The surface member 21 is not particularly limited. Examples of the surface member 21 include fabrics and leathers. Examples of fabrics include woven fabrics, knitted fabrics, and nonwoven fabrics. Examples of leathers include artificial leather, synthetic leather, and natural leather. Synthetic leathers include polyurethane leather and polyvinyl chloride leather. Natural leathers include split leather. The surface member 21 may be a composite of two or more of these materials.

[0026] The front member 21 is preferably a fibrous sheet material. The fibers forming the front member 21 are not particularly limited. However, the inventors believe that thermoplastic fibers are preferable from the viewpoints of the formability of the uneven pattern and durability. Examples of thermoplastic fibers include synthetic fibers and semi-synthetic fibers. Examples of synthetic fibers include polyester fibers, polypropylene fibers, and nylon fibers. Examples of semi-synthetic fibers include acetate fibers and triacetate fibers. The front member 21 may be formed of one type of fiber or a combination of two or more types of fibers.

[0027] The inventors believe that synthetic fibers are preferable as the fibers forming the surface member 21. Of the synthetic fibers, the inventors believe that polyester fibers are preferable, and polyethylene terephthalate fibers are more preferable. Synthetic fibers, polyester fibers, and polyethylene terephthalate fibers are excellent in the following physical properties. The aforementioned physical properties include strength, abrasion resistance, and heat resistance. As described above, the fibers forming the surface member 21 are preferably thermoplastic fibers. However, the fibers forming the surface member 21 may be combined with fibers other than thermoplastic fibers as long as the aforementioned physical properties are not affected. Examples of fibers other than thermoplastic fibers include natural fibers and recycled fibers. Examples of methods for combining thermoplastic fibers with other fibers include blending, interweaving, twisting, interweaving, and interknitting.

[0028] Examples of the cushion member 22 include synthetic resin foam, woven fabric, knitted fabric, and nonwoven fabric. However, the inventors believe that synthetic resin foam is preferable from the viewpoint of shapeability, and polyurethane foam is preferable from the viewpoint of versatility.

[0029] Examples of the backing member 23 include woven fabrics, knitted fabrics, and nonwoven fabrics. For example, the backing member 23 is used in consideration of the following first, second, and third points. The first point is to prevent the receiving member from being soiled when the recess 4 is formed. The receiving member will be described later. The second point is to reduce the process load. The backing member 23 allows the covering material 1 to slide smoothly against a sewing device when sewing the covering material 1 for a specified product or part. The third point is to prevent damage to the cushion member 22.

[0030] The thickness of the base material 2 is not particularly limited. However, from the viewpoint of shapeability, the thickness of the base material 2 is preferably 1.2 to 12.5 mm. The thickness of the cushion member 22 is not particularly limited. From the viewpoint of shapeability, the thickness of the cushion member 22 is preferably 1 to 10 mm, and more preferably 1 to 8 mm.

[0031] The substrate 2 may be colored with a known dye or pigment. The substrate 2 may be subjected to a pre-treatment and a post-treatment. Examples of the pre-treatment include presetting and scouring. Examples of the post-treatment include a processing to impart functionality and heat setting. Examples of the functions imparted by the processing to impart functionality include water repellency, stain resistance, and flame retardancy.

[0032] The recess 4 has a bottom and does not penetrate the substrate 2 (see FIG. 2). In this embodiment, the recess 4 includes a bottom surface and wall surfaces W1, W2, W3, and W4. The bottom surface and wall surfaces W1, W2, W3, and W4 of the recess 4 form the inner surface of the recess 4.

[0033] The shape of the recess 4 is not particularly limited. For example, the shape of the recess 4 may be a columnar, frustum, or cone shape whose bottom and open end have the following shapes. Examples of the aforementioned shapes include a circle, an ellipse, a polygon, a cloud, a star, and a flower. The bottom and open end of the recess 4 may have the same shape or different shapes. Different shapes include similar shapes. The shape of the recess 4 may be as follows when viewed from the front side in the thickness direction: In the above-mentioned shapes, the center of the bottom is shifted from the center of the open end. Furthermore, the bottom of the recess 4 does not have to be parallel to the surface 3. Alternatively, the bottom of the recess 4 does not have to be a plane, but may be a point or an edge. Examples of the shape of the open end of a recess 4 whose bottom is a point or an edge include a circle, an ellipse, a polygon, a cloud, a star, and a flower.

[0034] However, the inventors believe that the shape of the recesses 4 is preferably frustum-shaped or pyramidal-shaped from the following viewpoint: the aforementioned viewpoint is that misalignment between the recesses 4 and the colored portions 5 is unlikely to occur. When multiple recesses 4 are provided on the surface 3, the shape of one or both of the planar, dot-shaped, or edge-shaped bottom and the open end of the multiple recesses 4 may be different for some or all of them.

[0035] The colored portions 5 enhance the design of the skin material 1. In the skin material 1, colored portions such as the colored portions 5 provided in the recessed portions 4 are not provided on the surface 3 (see FIG. 1). The inventors believe that it may be preferable in some cases not to provide colored portions such as those described above on the surface 3. This may further enhance the design of the skin material 1. The colored portions will not peel off from the surface 3, improving the abrasion resistance of the skin material 1. However, the arrangement of the colored portions 5 relative to the recessed portions 4, the presence or absence of colored portions on the surface 3, and the arrangement of colored portions, if provided on the surface 3, are determined appropriately taking into account various conditions. For example, the design required for the skin material 1 is taken into consideration when making these decisions.

[0036] In the embodiment, the substrate 2 includes one colored portion 5 per recess 4 (see FIGS. 1 and 2). The substrate 2 may include multiple colored portions 5 per recess 4. In this case, the second color of the colored portions 5 may include multiple colors. That is, some or all of the multiple colored portions 5 in one recess 4 may be a different color from the other colored portions 5. In addition, when the substrate 2 includes multiple recesses 4 on the surface 3 (see FIGS. 1 and 2), the second color of the colored portions 5 may include multiple colors. That is, some or all of the colored portions 5 in the multiple recesses 4 may be a different color from the colored portions 5 in the other recesses 4. However, when the substrate 2 includes multiple colored portions 5 in one recess 4 or when the substrate 2 includes multiple recesses 4, the second color of all of the colored portions 5 may be the same color.

[0037] The colored portion 5 contains a colorant in addition to the binder resin described above. Examples of colorants include pigments, dyes, and metal powders. From the viewpoint of process load, the inventors believe that pigments are preferable as the colorant for the colored portion 5. The particle size of the colorant is not particularly limited. Colorants with particle sizes commonly used in ordinary resin prints can be used as the colorant for the colored portion 5.

[0038] As described above, it is important that the colored portion 5 contains one or both of a urethane resin and an acrylic resin as the binder resin. The inventors believe that urethane resin is preferable from the viewpoint of processability. Urethane resin reduces the problem of flammability and reduces tackiness during heat treatment. By using a resin with less tackiness, color unevenness in the colored portion 5 can be suppressed. Tackiness is an index related to adhesiveness.

[0039] Assume that the skin material 1 is a material for vehicle interior materials. In this case, it is important that the colored portion 5 contains at least a polycarbonate-based polyurethane resin as the urethane resin serving as the binder resin from the viewpoint of light resistance and heat resistance. In this case, the urethane resin serving as the binder resin may be one type, or a mixture of two or more types. For example, when the urethane resin serving as the binder resin is a mixture of two or more types, the binder resin may be a polycarbonate-based polyurethane resin mixed with the following polyurethane resin. For example, the aforementioned polyurethane resin may be one or both of a polyether-based polyurethane resin and a polyester-based polyurethane resin. However, the binder resin may contain a resin different from the aforementioned resins. The resin serving as the binder resin is appropriately determined taking into account various conditions. For example, the various properties required of the skin material 1 are taken into consideration when making this determination.

[0040] From the viewpoint of processability, it is important that the softening temperature of the urethane resin is 120 to 220°C. Furthermore, the softening temperature of the urethane resin is preferably 150 to 200°C. When the softening temperature of the urethane resin is 120°C or higher, the colorant-containing liquid composition held in the embossed portion is easily transferred to the substrate 2 during the manufacturing method of the skin material 1. Excellent processability can be obtained in the manufacturing method of the skin material 1. A colored portion 5 without color unevenness can be provided in the recessed portion 4. The embossed portion and the colorant-containing liquid composition will be described later. When the softening temperature of the urethane resin is 220°C or lower, the feel of the skin material 1 can be prevented from becoming rough and hard.

[0041] From the viewpoint of processability, it is important that the glass transition temperature (Tg) of the acrylic resin is -30 to 50°C. Furthermore, the glass transition temperature of the acrylic resin is preferably -20 to 20°C. When the glass transition temperature of the acrylic resin is -30°C or higher, the colorant-containing liquid composition held in the embossed portion is easily transferred to the substrate 2 during the manufacturing method of the skin material 1. Excellent processability can be obtained in the manufacturing method of the skin material 1. It is possible to provide colored portions 5 without color unevenness in the recesses 4. When the glass transition temperature of the acrylic resin is 50°C or lower, the feel of the skin material 1 can be prevented from becoming rough and hard.

[0042] The L between the first color of the base material 2 and the second color of the colored portion 5 * a * b * ΔE in color space * ab is set to 1.2 or more. ΔE between the first color and the second color * By setting ab to 1.2 or more, a viewer of the skin material 1 can clearly recognize the second color of the colored portion 5 as a different color from the first color surface 3. As a result, the design of the skin material 1 can be improved. * a * b * The color system is a method of representing colors that was standardized by the International Commission on Illumination (CIE 1976) and is also specified in JIS (JIS Z 8781-4). The method for measuring the first color of the base material 2 and the second color of the colored portion 5 will be described in the examples below.

[0043] The method for manufacturing the skin material 1 involves forming recesses 4 on the surface 3 of the substrate 2 and forming colored portions 5 in the recesses 4. In the method for manufacturing the skin material 1, the substrate 2 is placed between a pressing member and a receiving member, and the substrate 2 is pressed by the pressing member and the receiving member. The pressing member has an embossing portion. The pressing member is provided on the front side (the front member 21 side) of the substrate 2 in the thickness direction. When the substrate 2 is pressed, the pressing member comes into contact with the surface 3. The embossing portion has a shape corresponding to the recesses 4 and holds a colorant-containing composition. The colorant-containing composition contains the colorant described above. When the substrate 2 is pressed, the embossing portion bites into the substrate 2. According to the method for manufacturing the skin material 1, pressing the substrate 2 with the pressing member and the receiving member forms recesses 4 on the surface 3, and simultaneously forms colored portions 5. In the embodiments, the colorant-containing composition will be described as a colorant-containing liquid composition containing a colorant.

[0044] The method for processing the recesses 4 is not particularly limited. The method for processing the recesses 4 may include a step of forming the recesses 4 by the following method. In the above method, a pressing member having an embossing portion is used to press the substrate 2 from the front side to the back side in the thickness direction (from the front member 21 side to the back member 23 side). Examples of methods for processing the recesses 4 include embossing, welding, and pinsonic processing. The inventors believe that embossing is preferable from the standpoints of processing stability and cost.

[0045] In the embossing method, the substrate 2 is passed between a pressing member and a receiving member. In the embossing method, the substrate 2 passed between the pressing member and the receiving member is pressed by the pressing member and the receiving member, and recesses 4 are formed on the surface 3 of the substrate 2. As described above, the pressing member has an embossing portion shaped to correspond to the recesses 4.

[0046] As the embossing method, either a roll embossing method or a flat plate embossing method can be used. The shape of the pressing member may be a roll or a flat plate. The shape of the receiving member may be a smooth roll or a smooth plate. Furthermore, the pressing member and the receiving member may have the following recesses in the receiving member. The recesses described above correspond to the embossing portion. Pressing members and receiving members having such a shape are also called male and female dies. The pressing member and the receiving member can be used by appropriately combining dies having the shapes described above. However, the inventor believes that when a colored portion 5 is provided only on the bottom surface of the recess 4, it is preferable to use a combination of the pressing member and the receiving member other than the male and female dies.

[0047] The embossing portion is provided standing on the base surface of the pressing member. The embossing portion has a convex shape relative to the base surface of the pressing member. The base surface of the pressing member faces the surface 3 of the substrate 2 when the method for manufacturing the skin material 1 is carried out. The embossing portion bites into the substrate 2. The embossing portion holds a colorant-containing composition liquid and forms a colored portion 5 in the recess 4.

[0048] The shape of the embossed portion is not particularly limited. For example, the shape of the embossed portion may be a columnar, frustum, or cone shape when viewed from the front end of the embossed portion. Examples of the aforementioned shapes include a circle, an ellipse, a polygon, a cloud, a star, and a flower. The bottom and opening end of the recess 4 are assumed to be circular. In this case, the embossed portion has a convex shape whose top and rear end are the same as the bottom and opening end of the recess 4. The bottom and opening end of the recess 4 are assumed to be any of the above-mentioned elliptical, polygonal, cloud, star, and flower shapes. In this case, the embossed portion has a convex shape whose top and rear end are the same as the bottom and opening end of the recess 4.

[0049] The shape of the embossed portion may be as follows when viewed from the front end of the embossed portion. In the above-described embodiment, the center of the top surface is shifted from the center of the rear end. Furthermore, the top surface of the embossed portion does not have to be parallel to the base surface. In addition, the top of the embossed portion does not have to be a surface, but may be a point or an edge. Examples of the shape of the rear end of the embossed portion whose top is a point or an edge include a circle, an ellipse, a polygon, a cloud, a star, and a flower.

[0050] However, the inventors believe that it is preferable for the shape of the embossed portion to be frustum-shaped or cone-shaped from the following viewpoint: The aforementioned viewpoint is that the colored portion 5 can be easily provided at a desired position in the recess 4 without causing misalignment between the recess 4 and the colored portion 5. When multiple embossed portions are provided on the pressing member, the shape of one or both of the top and rear end of the planar, dot-shaped, or edge-shaped embossed portions may be different for some or all of the multiple embossed portions.

[0051] The colored portion 5 is provided on the bottom surface of the recess 4, but not on the wall surfaces W1, W2, W3, and W4. In this case, the outer peripheral corners of the top surface of the embossed portion preferably have a rounded shape. By making the outer peripheral corners of the top surface of the embossed portion rounded, the colorant-containing liquid composition can be retained on the top surface of the embossed portion while preventing the colorant-containing liquid composition from being retained on the side surfaces of the embossed portion. The side surfaces of the embossed portion are continuous with the top surface via the outer peripheral corners. This makes it difficult for the colorant-containing liquid composition to spill onto the wall surfaces W1, W2, W3, and W4 of the recess 4. This improves the design of the covering material 1. The colored portion 5 is provided on the wall surfaces W1, W2, W3, and W4. In this case, the outer peripheral corners of the top surface of the embossed portion preferably have a shape that is not rounded. A shape that is not rounded includes an embodiment in which the boundary between the top surface and the side surface is clear. The shape of the outer peripheral corners of the top surface of the embossed portion is determined appropriately depending on the arrangement of the colored portion 5 in the recess 4.

[0052] The embossed portion preferably has micro-irregularities on its surface. By providing micro-irregularities on the surface of the embossed portion, it is possible to make it easier for the embossed portion to retain the colorant-containing composition liquid. The area on the surface of the embossed portion where the micro-irregularities are provided is determined appropriately taking into consideration various conditions. For example, the micro-irregularities may be provided on one or both of the top surface and side surface of the embossed portion. When the micro-irregularities are provided on the top surface of the embossed portion, the micro-irregularities may be provided on part or all of the top surface. When the micro-irregularities are provided on the side surface of the embossed portion, the micro-irregularities may be provided on part or all of the side surface. When the embossed portion includes multiple side surfaces corresponding to the wall surfaces W1, W2, W3, and W4 of the recess 4, the micro-irregularities may be provided on part or all of the multiple side surfaces. In this case, on the side surface on which the micro-irregularities are provided, the micro-irregularities may be provided on part or all of the side surface. In addition, when the pressing member includes multiple embossed portions, the micro-irregularities may be provided on some or all of the embossed portions. Of the plurality of embossing portions, the embossing portion on which the minute concaves and convexes are to be formed is appropriately determined in consideration of various conditions.

[0053] When an embossed portion including minute concaves and convexes is compared with an embossed portion without minute concaves and convexes, the embossed portion including minute concaves and convexes can darkly color a predetermined region on the inner surface of the recessed portion 4. This allows the recessed portion 4 to be provided with a dark second colored portion 5, further improving the design of the skin material 1.

[0054] The shape of the minute irregularities, the depth of the recesses, and the interval between the recesses are not particularly limited. The shape of the minute irregularities, the depth of the recesses, and the interval between the recesses are appropriately determined taking into consideration the amount of the colorant-containing liquid composition to be retained. When the pressing member includes multiple embossing sections, the shape of the minute irregularities, the depth of the recesses, and the interval between the recesses may be different in some embossing sections from the other embossing sections, or may be the same in all embossing sections. Even in one embossing section, the shape of the minute irregularities may be different in some regions from the other regions, or may be the same in all regions.

[0055] The processing method for forming the minute concaves and convexes is not particularly limited. The minute concaves and convexes are formed on the surface of the embossed portion by a known processing method. Examples of processing methods for forming the minute concaves and convexes include sandblasting and laser engraving.

[0056] The colorant-containing liquid composition contains the above-mentioned colorant and a binder resin. The colorant-containing liquid composition may contain an additive. Examples of the additive include a solvent, a crosslinking agent, a catalyst, a leveling agent, a thickener, an antifoaming agent, and an anti-drying agent. The colorant-containing liquid composition preferably contains a solvent from the viewpoint of color matching to a desired color and viscosity adjustment. The solvent is preferably water from the viewpoint of environmental impact.

[0057] The viscosity of the colorant-containing liquid composition is preferably 5000 to 8000 mPa·s. By keeping the viscosity of the colorant-containing liquid composition within this range, the desired amount of colorant-containing liquid composition can be uniformly retained at the desired position of the embossed portion. If the viscosity of the colorant-containing liquid composition is less than 5000 mPa·s, the colorant-containing liquid composition becomes more fluid, and the amount of colorant-containing liquid applied to the recess 4 tends to be uneven. If the viscosity of the colorant-containing liquid composition is higher than 8000 mPa·s, the colorant-containing liquid composition tends to adhere to positions other than the desired position. The viscosity of the colorant-containing liquid composition is measured using a BM-type viscometer. For example, a measuring instrument manufactured by Toki Sangyo Co., Ltd. can be used as the BM-type viscometer, and a rotor No. 4 can be used. The rotation speed is set to 12 rpm. The measurement is performed in an environment set to 25°C ± 0.5°C.

[0058] The solid content of the colorant-containing liquid composition may be adjusted appropriately to obtain a desired color. However, a higher solid content of the colorant-containing liquid composition is preferable from the following viewpoint: high coloring properties can be obtained with a small amount of coating. For example, the solid content is preferably 35 to 55% by mass.

[0059] The method for applying the colorant-containing composition liquid to the embossed portion is not particularly limited. The colorant-containing composition liquid is applied to the embossed portion by a known method. Examples of the method for applying the colorant-containing composition liquid include transfer and coating.

[0060] The amount of the colorant-containing liquid composition to be applied to the embossed portion is not particularly limited. The amount of the colorant-containing liquid composition to be applied is determined appropriately taking into consideration various conditions. For example, the method of applying the colorant-containing liquid composition to the embossed portion and the design of the skin material 1 are taken into consideration when determining the amount.

[0061] The colorant-containing liquid composition is applied to the embossed portion by transfer. In this case, the thickness of the colorant-containing liquid composition is preferably 20 to 300 μm, and more preferably 50 to 150 μm. If the thickness of the colorant-containing liquid composition is less than 20 μm, the colorant-containing liquid composition is likely to be unevenly transferred to the recesses 4, which may impair the design of the skin material 1. If the thickness of the colorant-containing liquid composition is more than 300 μm, the colorant-containing liquid composition is likely to adhere to areas other than the desired position, which may impair the design of the skin material 1.

[0062] The pressing member holds the colorant-containing liquid composition in the embossing portion, and then moves relative to the receiving member. The embossing portion approaches the receiving member and presses it. As a result, the pressing member and the receiving member sandwich the substrate 2, and the embossing portion bites into the substrate 2 from the front side in the thickness direction. The embossing portion forms a recess 4 in the substrate 2 and also forms a colored portion 5 in the recess 4.

[0063] It is important that the temperature of the pressing member when pressing the substrate 2 is 80°C or less. Furthermore, the temperature of the pressing member when pressing the substrate 2 is preferably room temperature. In this case, the pressing member is not heated. When the temperature of the pressing member is 80°C or less, the colorant-containing composition liquid is less likely to dry after being applied to the substrate 2. The colorant-containing composition liquid is more likely to penetrate the substrate 2, and the substrate 2 and the colored portion 5 can be closely attached within the recess 4. The lower limit of the temperature of the pressing member when pressing the substrate 2 is not particularly limited. For example, the lower limit of the temperature of the pressing member may be 10°C or more.

[0064] From the viewpoint of shaping properties, the temperature of the receiving member when pressing the substrate 2 may be higher than the temperature of the pressing member. The temperature of the receiving member when pressing the substrate 2 may be higher than 80°C. The temperature of the receiving member when pressing the substrate 2 is preferably 220 to 280°C, and more preferably 220 to 240°C.

[0065] The conditions for pressing the substrate 2 with the pressing member and the receiving member are not particularly limited. Examples of the pressing conditions include the pressing force, pressing time, and processing speed. The conditions for pressing the substrate 2 are appropriately determined in consideration of various conditions so that the desired recesses 4 and colored portions 5 are obtained.

[0066] After forming the recesses 4 and the colored portions 5 in the base material 2, the pressing member moves relative to the receiving member and is separated from the receiving member. The skin material 1 is removed from the separated pressing member and receiving member. This allows the production of the following type of skin material 1. In the above-mentioned type, the recesses 4 are formed on the surface 3 of the base material 2, and the colored portions 5 are provided in the recesses 4 (see Figures 1 and 2).

[0067] After being removed from the pressing member and the receiving member, the skin material 1 may be heat-treated. The colorant-containing liquid composition can be completely dried by the heat treatment. The heat treatment can be carried out using a heat setter. In this case, the heat treatment is carried out at a temperature of 130 to 150°C for 30 seconds to 3 minutes.

[0068] The skin material 1 can be used as the outer surface of various products and parts. Examples of products and parts that can use the skin material 1 include transportation interior parts, interior goods, shoes, bags, and clothing. Transportation equipment includes automobiles, trains, airplanes, and ships. When the skin material 1 is used as a transportation interior part, the skin material 1 becomes a material that forms the following parts of the transportation equipment. Examples of the aforementioned parts include the ceiling, seats, dashboard, door lining, and steering wheel. Interior goods include furniture. Examples of furniture include sofas and chairs.

[0069] <Effects of the embodiment> According to the embodiment, the following effects can be obtained.

[0070] (1) The skin material 1 includes a substrate 2 (see FIGS. 1 and 2). The substrate 2 has a recess 4 on a surface 3. The substrate 2 includes a colored portion 5 of a second color in the recess 4. The second color is different from the first color of the substrate 2. The colored portion 5 includes a colorant and a binder resin. The binder resin includes one or both of a urethane resin that includes a polycarbonate-based polyurethane resin and has a softening temperature of 120°C or higher and 220°C or lower, and an acrylic resin that has a glass transition temperature of -30°C or higher and 50°C or lower.

[0071] With the skin material 1, the recesses 4 can be decorated with the colored portions 5. The tactile feel of the colored portions 5 can be made the same as or close to that of the non-colored portions. Light resistance and heat resistance can be ensured. Design features can be added to the skin material 1. The non-colored portions of the surface 3 of the skin material 1 are in the first color of the base material 2.

[0072] (2) The skin material 1 is a L color of the first color of the base material 2 and the second color of the colored portion 5. * a * b * ΔE in color space * ab is set to 1.2 or greater.

[0073] This configuration makes it possible to clearly distinguish the first color from the second color. For example, a viewer of the skin material 1 can distinguish the colored portion 5 on the surface 3 of the base material 2 and can recognize the colored portion 5 in the recess 4.

[0074] (3) The skin material 1 includes a substrate 2 (see FIGS. 1 and 2). The substrate 2 has a recess 4 on its surface 3. The substrate 2 includes a colored portion 5 of a second color in the recess 4. The recess 4 is formed by placing the substrate 2 between a pressing member and a receiving member and pressing the embossed portion of the pressing member against the substrate 2 in the following state. In the above state, the surface 3 of the substrate 2 is in contact with the pressing member, and the back surface of the substrate 2 is in contact with the receiving member. The embossed portion holds a colorant-containing liquid composition as a colorant-containing composition and has a shape corresponding to the recess 4. The colorant-containing composition contains a colorant of the second color. That is, the colorant-containing liquid composition contains a colorant of the second color. The pressing member is set to a first temperature of 80°C or less. The receiving member is set to a predetermined second temperature. The colored portion 5 is formed simultaneously with the recess 4 by the colorant-containing composition held by the embossed portion while the embossed portion is pressed against the substrate 2.

[0075] According to this covering material 1, the recessed portion 4 can be decorated with the colored portion 5. The abrasion resistance of the colored portion 5 can be improved. The covering material 1 can be given a design feature. [Example]

[0076] The inventors conducted experiments using 15 types of samples to confirm the effectiveness of the present invention. In the examples, the 15 types of samples are referred to as "Sample 1" to "Sample 15." When Samples 1 to 15 are not distinguished from one another or when they are referred to collectively, they are simply referred to as "samples." The samples include a substrate having a recess on its surface. The substrate includes, in the recess, a colored portion of a second color different from the first color of the substrate. Although details are omitted, the present invention is not limited to the configurations described below, as in the above-described embodiments.

[0077] <Evaluation items> The experiment was conducted on samples 1 to 15, and ΔE * ab, abrasion resistance, light resistance, heat resistance, sharpness of the pattern and feel were evaluated.

[0078] (1) ΔE * ab L of the substrate surface * , a * and b * and L of the colored part* , a * and b * and from these measurement results, ΔE * ab was calculated. The measurement of the first color of the substrate was carried out at any position (area) on the surface of the substrate, excluding the recessed portions provided on the surface of the substrate. The measurement of the second color of the colored portion was carried out at any position (area) on the surface of the colored portion. In formula (1), ΔL * , Δa * and Δb * is as follows: ΔL * is the L of the substrate * and L of the colored part * It is the difference between Δa * is the a of the substrate * and colored part a * The difference between Δb * is the b of the substrate * and b in the colored part * This is the difference between

number

[0079] L of the substrate * , a * and b * is the four L values ​​obtained by measuring any four points on the surface of the substrate. * , a * and b * The average value of the L of the colored part * , a * and b * is the four L values ​​obtained by measuring any four points on the surface of the colored part. * , a * and b * The measurement was performed using a spectrophotometer (Color I 5DV, manufactured by X-Rite). The light source was Illuminant C. ΔE * The case where ab was 1.2 or more was judged to be acceptable (see Tables 1 to 3 below).

[0080] (2) Abrasion resistance Abrasion resistance was evaluated using test pieces measuring 70 mm in width and 300 mm in length taken from the sample. One test piece was taken from the warp direction of the sample and one from the weft direction of the sample. The back of the test piece was covered with a sheet of paper measuring 70 mm in width, 300 mm in length, 10 mm in thickness, and 20 kg / m2 in specific gravity. 2 A piece of urethane foam measuring 1 / 4" in diameter was attached to the test piece. The test piece was then fixed to a T-TYPE flat abrasion tester (manufactured by Daiei Scientific Instruments Co., Ltd.). A load of 9.8 N was applied to a friction element covered with cotton cloth (JIS L3102: cotton canvas No. 6) to abrade the test piece. The friction element was abraded 10,000 times at a speed of 60 reciprocations per minute over a distance of 140 mm on the surface of the test piece. The abrasion resistance was evaluated by observing the test piece before and after abrasion and according to the following evaluation criteria. Abrasion resistance of grade 3 or higher was considered to be acceptable (see Tables 1 to 3 below). [Evaluation criteria] Grade 5: The pattern has not faded at all Grade 4: The handle is not worn, but there are signs of wear on the handle. Grade 3: The pattern has not disappeared, but it has faded a little. Grade 2: Part of the pattern has disappeared Grade 1: All of the pattern has disappeared (3) Light resistance Lightfastness was evaluated using a test piece 65 mm wide and 50 mm long taken from the sample. One test piece was taken from the longitudinal direction of the sample. The back of the test piece was 65 mm wide, 50 mm long, 10 mm thick, and had a specific gravity of 20 kg / m 2 A piece of urethane foam measuring 1 / 4 inch in diameter was then attached to the test specimen. The test specimen was then attached to a xenon weather meter (product name: Weather-O-Meter Ci4000, manufactured by Atlas). Assuming that the skin material was a vehicle interior material, ultraviolet-blocking glass was attached to the front side of the test specimen. The test conditions were a black panel temperature of 89±3°C, humidity of 50±5% RH, and irradiation intensity (cumulative irradiation amount) of 40 MJ / m 2 and total irradiation dose of 750 kJ / m 2 The surface appearance of the test piece was visually observed before and after irradiation. The lightfastness was evaluated by comparing the test piece before and after irradiation and evaluating the degree of discoloration of the test piece after irradiation using a gray scale for discoloration (JIS L0804). Lightfastness of grade 3 or higher was considered to be acceptable (see Tables 1 to 3 below).

[0081] (4) Heat resistance Heat resistance was evaluated using test pieces measuring 100 mm in width and 100 mm in length taken from the sample. One test piece was taken from the warp direction of the sample and one from the weft direction of the sample. The test pieces were placed in a Gear-type heat aging tester (a rotating frame incubator <Gear oven> GPH(H), manufactured by Espec Corporation) and heat-treated at 110°C for 400 hours. The test pieces were then removed from the Gear-type heat aging tester and cooled to room temperature. The surface appearance of the test pieces was then visually observed. Heat resistance was evaluated by comparing the test pieces before and after heat treatment and evaluating the degree of discoloration of the test pieces after heat treatment using the discoloration gray scale (JIS L0804). Heat resistance of grade 4 or higher was considered acceptable (see Tables 1 to 3 below).

[0082] (5) Sharpness of the pattern The sharpness of the pattern was evaluated by sensory evaluation according to the following evaluation criteria. A pattern with a sharpness of B or higher was considered to be acceptable (see Tables 1 to 3 below). [Evaluation criteria] A: There are no chips or protrusions in the colored part of the recessed area. B: There is some chipping or protrusion in the colored part of the recess. C: There is a chip or protrusion in the colored part of the recess. (6)Tactile sensation The texture was evaluated by sensory evaluation according to the following evaluation criteria. A texture of B or higher was rated as passing (see Tables 1 to 3 below). [Evaluation criteria] A: The colored and uncolored parts have almost the same texture. B: The colored part feels a little harder than the non-colored part, but it's not noticeable. C: The colored part feels significantly harder than the non-colored part. <Production method and evaluation results> (1) Sample 1 (1-1) Manufacturing method In Sample 1, the substrate includes a front member and a cushion member. The front member is a dobby-woven fabric. A dobby loom was used for weaving. The warp yarns were 167 dtex / 48f polyester multifilament semi-dull textured yarns. The weft yarns were 167 dtex / 48f / 2 polyester multifilament semi-dull textured yarns. The warp yarn density was 145 / 25.4 mm. The weft yarn density was 75 / 25.4 mm. After weaving, the fabric was heat-treated. A heat setter was used for the heat treatment. The heat treatment conditions were 190°C for 1 minute. This heat treatment is called presetting. Next, the fabric was dyed gray using a jet dyeing machine. A disperse dye (DIANIX BLACK HLA, manufactured by Dystar Japan Co., Ltd.) was used at a dye concentration of 2.0% owf. The treatment conditions were 130°C for 30 minutes. After dyeing, the fabric was dehydrated and heat-treated. A heat setter was used for the heat treatment. The heat treatment was first performed at 130°C for 2 minutes, and then at 150°C for 1 minute. The first heat treatment dries the fabric. The subsequent heat treatment is called setting. Upon completion of the subsequent heat treatment, the outer surface is obtained.

[0083] After the front member was prepared, an 11 mm thick cushion member was laminated on the back surface of the front member. The cushion member was a polyurethane foam sheet (EL67F, manufactured by Inoac Corporation). Frame lamination was used to laminate the front member and cushion member. A substrate was obtained by laminating the front member and cushion member. The front member forms the surface of this substrate.

[0084] Next, a colorant-containing composition liquid prepared according to the following formula 1 was applied to a flat iron plate. The thickness of the colorant-containing composition liquid applied to the iron plate was 200 μm. Formula 1 was prepared by mixing the raw materials contained in Formula 1 using a mixer. In preparing Formula 1, a thickener and an aqueous ammonia solution were added to achieve a viscosity of 5000 mPa·s. A BM-type viscometer manufactured by Toki Sangyo Co., Ltd. and a rotor No. 4 were used to measure the viscosity. The rotation speed was set to 12 rpm. The measurement was carried out in an environment set to 25°C ± 0.5°C. [Prescription 1] Binder resin: 90% by mass (urethane resin (polycarbonate-based polyurethane resin, polyether-based polyurethane resin), Hydran WLS-221, manufactured by DIC Corporation, solid content 35% by mass, softening temperature 160°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount Next, recesses and colored portions were formed on the surface of the substrate. A flat embossing machine was used to form the recesses and colored portions. The flat embossing machine includes a flat pressing member and a flat receiving member. The pressing member was configured as shown in Figures 3 and 4. This pressing member corresponds to a border pattern. The specifications of the pressing member are as follows (see Figures 3 and 4 for the longitudinal direction, lateral direction, heights H, H1, H2, and curve radius R): [Pushing member specifications] Pusher dimensions (longitudinal and transverse directions): 200mm, 150mm Shape of embossing part (top surface, rear end): Rectangle, rectangle Dimensions of the embossing part (top surface, height H): 1.0 mm x 150 mm (longitudinal direction x transverse direction), 7 mm (height H1: 2 mm, height H2: 5 mm) R shape of the embossed part: Yes (curve radius R: 0.6 mm) Micro-irregularities in the embossed area: None Prior to forming the recesses and colored portions, a colorant-containing composition liquid was applied to the top surface of the embossed portion of the pressing member by the following transfer method. In the above method, the iron plate coated with the colorant-containing composition liquid was placed on the receiving member in the following state. In the above state, the iron plate was parallel to the top surface of the embossed portion of the pressing member. The flat plate embossing machine was adjusted to the following state. In the above state, when the pressing member and the receiving member were brought close to each other, the clearance between the top surface of the embossed portion and the iron plate was 150 μm. Next, the pressing member pressed the iron plate on the receiving member, and then the pressing member and the receiving member were separated. The colorant-containing composition liquid was applied to the top surface of the embossed portion, but not to the side surfaces of the embossed portion.

[0085] The substrate was then placed on a receiving member heated to 230°C, and a room-temperature pressing member was pressed against the surface of the substrate at a pressure of 8 MPa for 10 seconds. The substrate was removed from between the pressing member and receiving member and then heat-treated in a heat setter at 150°C for 1 minute. The resulting skin material was designated Sample 1.

[0086] (1-2) Evaluation results In Sample 1, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 1, ΔE * The ab score was 27, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored part, and the sharpness of the pattern was graded A. The colored part had almost the same feel as the uncolored part, and the feel was graded A.

[0087] (2) Sample 2 (2-1) Manufacturing method The method for producing Sample 2 differs from the method for producing Sample 1 in the following respects. The aforementioned point is the temperature of the pressing member when forming the recesses and colored portions using a flat embossing machine. In the method for producing Sample 2, the pressing member was heated to 85°C. Other than this, the method for producing Sample 2 is the same as that for Sample 1. Other explanations regarding the method for producing Sample 2 will be omitted.

[0088] (2-2) Evaluation results In Sample 2, a colored portion of a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 2, ΔE * The ab was 31, and the design was good. The abrasion resistance was grade 3. In sample 2, it was observed that parts of the colored parts easily peeled off when rubbed. This was because the colored parts were in an upturned state, and the resin forming the colored parts was not in close contact with the surface member. The upturned state of the colored parts is likely to occur when the colorant-containing composition liquid solidifies without penetrating into the surface member. The light resistance was grade 4, and the heat resistance was grade 4. No chipping or spillage was observed in the colored parts, and the sharpness of the pattern was grade A. The colored parts had almost the same feel as the uncolored parts, and the feel was grade A.

[0089] Sample 2 exhibits excellent design and meets the pass criteria in all evaluations. The inventor believes that the skin material of Sample 2 can be used as the surface of many products and parts. The inventor believes that the skin material of Sample 2 is suitable as the surface of products and parts where something does not or will not rub strongly against the colored part in the recess.

[0090] (3) Sample 3 (3-1) Manufacturing method The method for producing Sample 3 differs from that for Sample 1 in the following respects. The aforementioned point is the coating thickness of the colorant-containing composition liquid applied to the flat iron plate. Furthermore, the aforementioned point is the clearance between the top surface of the embossed portion and the iron plate when the colorant-containing composition liquid on the iron plate is applied to the top surface of the embossed portion. In the method for producing Sample 3, the coating thickness of the colorant-containing composition liquid was 350 μm, and the clearance between the top surface of the embossed portion and the iron plate was 300 μm. The method for producing Sample 3 is the same as that for Sample 1 except for the two points mentioned above. Other explanations regarding the method for producing Sample 3 will be omitted.

[0091] (3-2) Evaluation results In Sample 3, a colored portion of a color (second color) different from the gray color (first color) of the surface of the substrate was provided on the bottom surface of the recess. However, in Sample 3, slight adhesion of the resin forming the colored portion was also observed on the wall surface of the recess. ΔE * ab is 28, for example, ΔE * The coloring was slightly improved compared to Sample 1, which had an ab of 27, but the design was slightly inferior to Sample 1. This was due to the lack of sharpness of the pattern at the boundary between the bottom and wall of the recess. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. As mentioned above, with Sample 3, bleeding into the colored areas was observed, so the sharpness of the pattern was graded B. The colored areas had almost the same feel as the uncolored areas, and the feel was graded A.

[0092] Although Sample 3 was slightly inferior in design in terms of the sharpness of the pattern compared to Sample 1, it had a ΔE * The ab scores are high and all evaluations meet the pass criteria. The inventor believes that the skin material of Sample 3 can be used as the outer surface of many products and parts. The inventor believes that the skin material of Sample 3 is suitable as the outer surface of products and parts that do not require high quality in terms of sharpness of the pattern.

[0093] (4) Sample 4 (4-1) Manufacturing method The manufacturing method of Sample 4 differs from that of Sample 1 in the following respects. The aforementioned point is that the embossing portion of the pressing member has minute irregularities on the top surface. The form of the minute irregularities is a pyramidal mesh with a side length of 0.38 mm and a depth of 0.05 mm. Other than this point, the manufacturing method of Sample 4 is the same as that of Sample 1. Other explanations regarding the manufacturing method of Sample 4 will be omitted.

[0094] (4-2) Evaluation results In Sample 4, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 4, ΔE *The ab score was 29, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored part, and the sharpness of the pattern was graded A. The colored part had almost the same feel as the uncolored part, and the feel was graded A.

[0095] (5) Sample 5 (5-1) Manufacturing method The method for producing Sample 5 differs from that for Sample 1 in the following respects. The aforementioned point is that the embossed portion of the pressing member has minute irregularities on its top surface. The minute irregularities are in the form of a pyramidal mesh with a side length of 0.38 mm and a depth of 0.05 mm. Furthermore, the aforementioned point is that the colorant-containing composition liquid of Formulation 1 was applied to the top surface and side surface of the embossed portion. The colorant-containing composition liquid was applied to the top surface and side surface of the embossed portion by pressing the pressing member against a sponge soaked in the colorant-containing composition liquid. During this process, the colorant-containing composition liquid was prevented from adhering to the base surface of the pressing member. The sponge thickness was 20 mm. The method for producing Sample 5 was the same as that for Sample 1 except for the two points mentioned above. Further explanation of the method for producing Sample 5 will be omitted.

[0096] (5-2) Evaluation results In Sample 5, only the bottom and wall surfaces of the recesses were provided with colored portions of a color (second color) different from the gray color (first color) of the surface of the substrate. In Sample 5, ΔE * The ab score was 25, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored part, and the sharpness of the pattern was graded A. The colored part had almost the same feel as the uncolored part, and the feel was graded A.

[0097] (6) Sample 6 (6-1) Manufacturing method The method for preparing Sample 6 differs from that for Sample 1 in the following respect. The aforementioned point is that the composition of the colorant-containing composition liquid is Formulation 2 below. Other than this, the method for preparing Sample 6 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 6 will be omitted. [Prescription 2] Binder resin: 90% by mass (Acrylic resin, Sanacryl NH-18, manufactured by Murayama Chemical Laboratory Co., Ltd., solid content 44% by mass, glass transition temperature -10°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (6-2) Evaluation results In Sample 6, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 6, ΔE * The ab score was 26, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored part, and the sharpness of the pattern was graded A. The colored part had almost the same feel as the uncolored part, and the feel was graded A.

[0098] (7) Sample 7 (7-1) Manufacturing method The method for preparing Sample 7 differs from that for Sample 1 in the following respect. The aforementioned point is that the colorant-containing composition liquid has the following formulation 3. Other than this, the method for preparing Sample 7 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 7 will be omitted. [Prescription 3] Binder resin: 90% by mass (Urethane resin (polycarbonate-based polyurethane resin), Superflex 420, manufactured by Daiichi Kogyo Seiyaku Co., Ltd., solid content 32% by mass, softening temperature 198°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (7-2) Evaluation results In Sample 7, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 7, ΔE * The ab score was 28, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored part, and the sharpness of the pattern was graded A. The colored part felt a little harder than the uncolored part, but the feel was not noticeable, and the feel was graded B.

[0099] Sample 7 exhibits excellent design and meets the pass criteria in all evaluations. The inventor believes that the skin material of Sample 7 can be used as the outer surface of many products and parts. The inventor believes that the skin material of Sample 7 is suitable as the outer surface of products and parts that do not require high quality in the tactile feel of the colored part in the recess, or as the outer surface of products and parts where this colored part does not come into direct contact with the user's skin.

[0100] (8) Sample 8 (8-1) Manufacturing method The method for preparing Sample 8 differs from that for Sample 1 in the following respect. The aforementioned point is that the composition of the colorant-containing composition liquid is Formulation 4 below. Other than this, the method for preparing Sample 8 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 8 will be omitted. [Formulation 4] Binder resin: 90% by mass (Acrylic resin, Boncoat AN-1190, manufactured by DIC Corporation, solid content 45% by mass, glass transition temperature 40°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (8-2) Evaluation results In Sample 8, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 8, ΔE * The ab score was 29, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored parts, and the sharpness of the pattern was graded A. The colored parts felt a little harder than the uncolored parts, but this was not noticeable, and the feel was graded B.

[0101] Sample 8 exhibits excellent design and meets the pass criteria in all evaluations. The inventor believes that the skin material of Sample 8 can be used as the outer surface of many products and parts. The inventor believes that the skin material of Sample 8 is suitable as the outer surface of products and parts that do not require high quality in the tactile feel of the colored part in the recess, or as the outer surface of products and parts where this colored part does not come into direct contact with the user's skin.

[0102] (9) Sample 9 (9-1) Manufacturing method The method for preparing Sample 9 differs from that for Sample 1 in the following respect. The aforementioned point is that the composition of the colorant-containing composition liquid is Formulation 5 below. Other than this, the method for preparing Sample 9 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 9 will be omitted. [Formulation 5] Binder resin: 50% by mass (Urethane resin (polycarbonate-based polyurethane resin), Superflex 420, manufactured by Daiichi Kogyo Seiyaku Co., Ltd., solid content 32% by mass, softening temperature 198°C) Binder resin: 25% by mass (Acrylic resin, Nuplex HC-860V, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass, glass transition temperature -17°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (9-2) Evaluation results In Sample 9, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 9, ΔE * The ab score was 27, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored part, and the sharpness of the pattern was graded A. The colored part had almost the same feel as the uncolored part, and the feel was graded A.

[0103] (10) Sample 10 (10-1) Manufacturing method The method for producing Sample 10 differs from that for Sample 1 in the following respect. The aforementioned point is the temperature of the pressing member when forming the recesses and colored portions using a flat embossing machine. In the method for producing Sample 10, the pressing member was heated to 110°C. Other than this point, the method for producing Sample 10 is the same as that for Sample 1. Other explanations regarding the method for producing Sample 10 will be omitted.

[0104] (10-2) Evaluation results In Sample 10, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 10, ΔE *The ab score was 33, and the design was good. The abrasion resistance was grade 2, which did not meet the pass criteria. This was because the colored parts were in an upward-facing state, and the resin forming the colored parts was not in close contact with the surface material. The upward-facing state of the colored parts is as described above in relation to the evaluation results of Sample 2. The light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored parts, and the sharpness of the pattern was graded A. The colored parts had almost the same feel as the uncolored parts, and the feel was graded A.

[0105] Sample 10 exhibits excellent design and meets the pass criteria in all evaluations except for abrasion resistance. The inventor believes that although the covering material of Sample 10 is difficult to use as the outer surface of some products and parts, there are products and parts for which it can be used as the outer surface. The inventor believes that the covering material of Sample 10 is suitable as the outer surface of products and parts where objects do not or are unlikely to rub against the colored portion in the recess.

[0106] (11) Sample 11 (11-1) Manufacturing method The method for preparing Sample 11 differs from that for Sample 1 in the following respect. The aforementioned point is that the composition of the colorant-containing composition liquid is Formulation 6 below. Other than this, the method for preparing Sample 11 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 11 will be omitted. [Formulation 6] Binder resin: 90% by mass (Urethane resin (polyether polyurethane resin), Hydran WLS-201, manufactured by DIC Corporation, solid content 35% by mass, softening temperature 110°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (11-2) Evaluation results In Sample 11, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 11, ΔE * The ab score was 24. However, in terms of design, chipping was observed in the colored portions of Sample 11. The abrasion resistance was grade 4, the light resistance was grade 2-3, and the heat resistance was grade 3. The light resistance and heat resistance did not meet the pass criteria. The decrease in light resistance and heat resistance is thought to be due to the fact that the urethane resin used as the binder resin was a polyether-based polyurethane resin and did not contain a polycarbonate-based polyurethane resin. As mentioned above, chipping was observed in the colored portions of Sample 11, so the sharpness of the pattern was rated C. The sharpness of the pattern did not meet the pass criteria. When forming the recesses and colored portions using a flat embossing machine, stringing occurred when the colorant-containing composition applied to the embossing portion of the pressing member separated from the embossing portion. The chipping in the colored portions is thought to be caused by this stringing, which prevented part of the colorant-containing composition from being neatly transferred to the surface of the substrate forming the bottom of the recesses. The stringiness is thought to be caused by the low softening temperature of the polyether polyurethane resin used as the binder resin, at 110°C. The colored portion had almost the same feel as the uncolored portion, and was rated an A.

[0107] (12) Sample 12 (12-1) Manufacturing method The method for preparing Sample 12 differs from that for Sample 1 in the following respect. That is, the colorant-containing liquid composition has the following formula 7. Other than this, the method for preparing Sample 12 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 12 will be omitted. [Formulation 7] Binder resin: 90% by mass (Acrylic resin, AE181C, manufactured by E-Tech Co., Ltd., solid content 35.5% by mass, glass transition temperature 90°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (12-2) Evaluation results In Sample 12, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 12, ΔE * The ab was 28, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. No chipping or overflow was observed in the colored parts, and the sharpness of the pattern was graded A. The colored parts felt significantly harder than the uncolored parts, and the feel was graded C. The feel did not meet the pass criteria. The poor feel is thought to be due to the high glass transition temperature of 90°C of the acrylic resin used as the binder resin.

[0108] (13) Sample 13 (13-1) Manufacturing method The method for preparing Sample 13 differs from that for Sample 1 in the following respect. The aforementioned point is that the colorant-containing composition liquid has the following formulation 8. Other than this, the method for preparing Sample 13 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 13 will be omitted. [Formulation 8] Binder resin: 90% by mass (Urethane resin (polyether polyurethane resin), Hydran WLS-202, manufactured by DIC Corporation, solid content 35% by mass, softening temperature 160°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (13-2) Evaluation results In Sample 13, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 13, ΔE * The ab was 26, and the design was good. The abrasion resistance was grade 4, the light resistance was grade 2-3, and the heat resistance was grade 3-4. The light resistance and heat resistance did not meet the pass criteria. The decrease in light resistance and heat resistance is thought to be due to the fact that the urethane resin used as the binder resin is a polyether-based polyurethane resin and does not contain a polycarbonate-based polyurethane resin. No chipping or overflow was observed in the colored parts, and the sharpness of the pattern was graded A. The colored parts had almost the same feel as the uncolored parts, and the feel was graded A.

[0109] (14) Sample 14 (14-1) Manufacturing method The method for preparing Sample 14 differs from that for Sample 1 in the following respect. The aforementioned point is that the colorant-containing composition liquid has the following formulation 9. Other than this, the method for preparing Sample 14 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 14 will be omitted. [Formulation 9] Binder resin: 90% by mass (Acrylic resin Boncoat AB-886, manufactured by DIC Corporation, solid content 50% by mass, glass transition temperature -38°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (14-2) Evaluation results In Sample 14, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 14, ΔE * The ab score was 25. However, in terms of design, chipping was observed in the colored parts of sample 14. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. As mentioned above, chipping was observed in the colored parts of sample 14, so the sharpness of the pattern was given a C. The sharpness of the pattern did not meet the pass criteria. The chipping in the colored parts is thought to be due to the low glass transition temperature of -38°C of the acrylic resin used as the binder resin. The colored parts had almost the same feel as the uncolored parts, and the feel was given an A.

[0110] (15) Sample 15 (15-1) Manufacturing method The method for preparing Sample 15 differs from that for Sample 1 in the following respect. The aforementioned point is that the composition of the colorant-containing composition liquid is Formulation 10 shown below. Other than this, the method for preparing Sample 15 is the same as that for Sample 1. Other explanations regarding the method for preparing Sample 15 will be omitted. [Formulation 10] Binder resin: 90% by mass (Acrylic resin Boncoat AN-1170, manufactured by DIC Corporation, solid content 50% by mass, glass transition temperature 60°C) Colorant: 1% by mass (Pigment, RYUDAYE-W YELLOW FF7G, manufactured by DIC Corporation, solid content 25% by mass) Colorant: 2% by mass (Pigment, titanium paste, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) Water: 2% by mass Thickener: appropriate amount (Boncoat VE, manufactured by DIC Corporation, solid content 30% by mass) 25% ammonia solution: appropriate amount (15-2) Evaluation results In Sample 15, a colored portion having a color (second color) different from the gray color (first color) of the surface of the substrate was provided only on the bottom surface of the recess. In Sample 15, ΔE * The ab score was 28. However, in terms of design, cracks were observed in the colored parts of Sample 15. The abrasion resistance was grade 4, the light resistance was grade 4, and the heat resistance was grade 4. As mentioned above, cracks were observed in the colored parts of Sample 15, so the sharpness of the pattern was graded B. The colored parts felt significantly harder than the uncolored parts, and the tactile feel was graded C. The tactile feel did not meet the pass criteria. The cracks in the colored parts and the deterioration in tactile feel are thought to be caused by the high glass transition temperature of 60°C of the acrylic resin used as the binder resin.

[0111] The pass criteria for the above-mentioned evaluation items and the evaluation results for Samples 1 to 15 are summarized in Tables 1 to 3. [Table 1] [Table 2] [Table 3] [Explanation of symbols]

[0112] 1 skin material, 2 base material, 21 surface member, 22 cushion member 23 backing member, 3 surface, 4 recess, 5 colored portion W1, W2, W3, W4 walls

Claims

1. a substrate having a recess having a base and an inner peripheral surface on a surface of a first color; The substrate is A laminate including a surface member whose surface in the thickness direction of the base material forms the surface of the base material, and a cushion member made of polyurethane foam laminated on the back side of the surface member in the thickness direction, The first color is L ＊ a ＊ b ＊ ΔE in color system ＊ a colored portion of a second color where ab is different in the range of 26 to 31; The inner circumferential surface is a first portion inclined from a second side to a first side in a first direction perpendicular to the thickness direction from a back side to a front side in the thickness direction; a second portion inclined from the first side to the second side in the first direction from the back side to the front side in the thickness direction on a second side in the first direction, a dimension in the first direction of an opening end of the recess that is a front side in the thickness direction is set to be larger than a dimension in the first direction of the bottom surface, The colored portion is A colorant; a binder resin, the binder resin includes one or both of a urethane resin that includes a polycarbonate-based polyurethane resin and has a softening temperature of 120°C or higher and 220°C or lower, and an acrylic resin that has a glass transition temperature of -30°C or higher and 50°C or lower; The colored portion is not provided on the inner circumferential surface but is provided on the bottom surface.

2. A substrate having a recess having a bottom surface and an inner peripheral surface on a surface of a first color, The substrate is A laminate including a surface member whose front surface forms the surface of the base material, and a cushion member made of polyurethane foam laminated on the back side of the surface member, the recess includes a colored portion of a second color that is different from the first color in ΔE*ab in the L*a*b* color system by 26 to 31; The colored portion is A colorant; a binder resin, the binder resin includes one or both of a urethane resin that includes a polycarbonate-based polyurethane resin and has a softening temperature of 120°C or higher and 220°C or lower, and an acrylic resin that has a glass transition temperature of -30°C or higher and 50°C or lower; The colored portion is not provided on the inner circumferential surface but is provided on the bottom surface, a pressing member having a first temperature of 80°C or less, the pressing member holding a colorant-containing composition containing the second colorant and including an embossed portion having a shape corresponding to the recessed portion, and the pressing member having a first temperature of 80°C or less, and a back surface of the substrate being in contact with a receiving member having a predetermined second temperature, the substrate is disposed between the pressing member and the receiving member, and the embossed portion is pressed against the substrate to form the recessed portion; a method for producing a skin material, the method comprising: forming the colored portion simultaneously with the recessed portion by the colorant-containing composition held by the embossed portion while the embossed portion is pressed against the substrate;

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